U.S. patent application number 15/157164 was filed with the patent office on 2016-11-17 for system and method for grinding a meat patty.
The applicant listed for this patent is Momentum Machines Company. Invention is credited to James Brinkman, Steven Frehn, Alexandros Vardakostas.
Application Number | 20160330982 15/157164 |
Document ID | / |
Family ID | 57275822 |
Filed Date | 2016-11-17 |
United States Patent
Application |
20160330982 |
Kind Code |
A1 |
Frehn; Steven ; et
al. |
November 17, 2016 |
SYSTEM AND METHOD FOR GRINDING A MEAT PATTY
Abstract
One variation of a system for forming a meat patty includes: a
cylinder operable in a upright position and an inverted position; a
piston running within the cylinder and defining a set of gas ports;
a grinder configured to grind meat and to dispense a quantity of
ground meat into the cylinder, in the upright position, during a
grind cycle; an actuator system configured to transition the
cylinder from the upright position to the inverted position during
a dispense cycle to dispense the quantity of ground meat from the
cylinder; and a gas supply configured to supply gas to the cylinder
behind the piston at a first pressure during the grind cycle to
limit ingress of ground meat into the gas ports and at a second
pressure greater than the first pressure during the dispense cycle
to dislodge the quantity of ground meat from the piston.
Inventors: |
Frehn; Steven; (San
Francisco, CA) ; Vardakostas; Alexandros; (San
Francisco, CA) ; Brinkman; James; (San Francisco,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Momentum Machines Company |
San Francisco |
CA |
US |
|
|
Family ID: |
57275822 |
Appl. No.: |
15/157164 |
Filed: |
May 17, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62162796 |
May 17, 2015 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A22C 7/0023 20130101;
A22C 7/0046 20130101; B02C 18/305 20130101; B02C 25/00 20130101;
A22C 7/0076 20130101; A22C 7/003 20130101 |
International
Class: |
A22C 7/00 20060101
A22C007/00; B02C 25/00 20060101 B02C025/00; A23L 13/00 20060101
A23L013/00; B02C 18/30 20060101 B02C018/30 |
Claims
1. A system for forming a meat patty comprising: a cylinder
operable in an upright position and an inverted position; a piston
running within the cylinder and defining a set of gas ports; a
grinder configured to grind meat and to dispense a quantity of
ground meat onto the piston in the cylinder during a grind cycle,
the cylinder in the upright position during the grind cycle; an
actuator system configured to transition the cylinder from the
upright position to the inverted position during a dispense cycle
to dispense the quantity of ground meat in the form of a patty from
the cylinder; and a gas supply: configured to supply gas to the
cylinder behind the piston at a first pressure during the grind
cycle to limit ingress of ground meat into the gas ports; and
configured to supply gas to the cylinder behind the piston at a
second pressure greater than the first pressure during the dispense
cycle to dislodge the quantity of ground meat from the piston.
2. The system of claim 1, wherein the piston is operable between
(i) an unload position that is proximal a top of the cylinder and
(ii) a load position that is offset below the top of the cylinder;
and wherein the actuator system is configured to transition the
piston from the load position to the unload position during the
dispense cycle.
3. The system of claim 2, wherein the actuator system comprises: a
gearbox coupled to the cylinder and coupled to the piston via a
connecting rod; a first actuator configured to rotate the gearbox
in a first direction to transition the cylinder from the upright
position to the inverted position and to transition the piston from
the load position to the unload position once the cylinder is
inverted and configured to rotate the gearbox in a second direction
to transition the cylinder from the inverted position to the
upright position and to transition the piston from the unload
position to the load position once the cylinder is righted; and a
second actuator configured to shift the cylinder laterally from an
outlet of the grinder.
4. The system of claim 2, further comprising a controller
configured to receive a food order for a hamburger patty and to
calculate an offset distance between the unload position and the
load position based on a target size of the hamburger patty
specified in the food order.
5. The system of claim 2, further comprising a load sensor;
wherein, during a grind cycle, the actuator system is configured to
hold the piston in the load position; and wherein the grinder is
configured to cease dispensation of ground meat into the cylinder
in response to an output of the load sensor exceeding a threshold
value.
6. The system of claim 5, wherein the actuator system comprises a
beam supporting the cylinder on a cantilevered end of the beam;
wherein the load sensor is configured to output a signal
corresponding to deflection of the beam; and wherein the grinder is
configured to cease dispensation of ground meat into the cylinder
in response to an output of the load sensor exceeding the threshold
value correlated with deflection of the beam at complete loading of
the cylinder.
7. The system of claim 2, further comprising a position sensor
configured to output a signal corresponding to a position of the
piston; wherein the actuator system is configured to hold the
piston in the unload position in preparation for the grind cycle;
and wherein the grinder is configured to cease dispensation of
ground meat into the cylinder in response to an output of the
position sensor indicating displacement of the piston to the load
position by the quantity of ground meat dispensed into the cylinder
by the grinder.
8. The system of claim 5, further comprising a controller
configured to estimate a first grind duration based on a target
weight of a hamburger patty; further comprising a load sensor
configured to output a signal corresponding to a weight of ground
meat in the cylinder; wherein the grinder is configured to grind
meat cubes and to dispense a first quantity of ground meat into the
cylinder for the first grind duration during a first grind cycle;
wherein the controller determines a weight of the first quantity of
ground meat based on an output of the load sensor upon conclusion
of the first grind cycle; wherein, in response to the weight of the
first quantity of ground meat exceeding a minimum weight threshold,
the controller triggers the actuation system to execute a first
dispense cycle; and wherein, in response to the minimum weight
threshold exceeding the weight of the first quantity of ground
meat, the controller: calculates a second grind duration based on a
difference between the target weight of the hamburger patty and the
weight of the first quantity of ground meat, triggers the grinder
to dispense additional ground meat into the cylinder for the second
grind duration, and estimates a third grind duration for a
subsequent grind cycle based on a sum of the first grind duration
and the second grind duration.
9. The system of claim 1, further comprising: a shear assembly
interposed between an outlet of the grinder and a top of the
cylinder and operable between a retracted position and an advanced
position, wherein the shear assembly is configured to transition
from the retracted position to the advanced position following
actuation of the grinder during the grind cycle to separate ground
meat between the outlet of the grinder and the top of the
cylinder.
10. The system of claim 9, wherein the piston is operable between
(i) an unload position that is proximal a top of the cylinder and
(ii) a load position that is offset below the top of the cylinder;
wherein the actuator system is configured to transition the piston
to the load position in preparation for a grind cycle; and wherein,
upon conclusion of the grind cycle and before initiation of the
dispense cycle, the actuator system drives the piston toward the
shear assembly to compress the quantity of ground meat into a patty
between the piston and the shear assembly.
11. The system of claim 10, wherein the actuator system drives the
piston toward the shear assembly by a target distance to compress
the quantity of ground meat into a hamburger patty between the
piston and the shear assembly, the target distance correlated with
a patty compaction level corresponding to a doneness level
specified for the hamburger patty in a food order.
12. The system of claim 1, further comprising: a hopper configured
to store whole portions of meat; a lower auger configured to drive
whole portions of meat into the grinder; and an upper auger geared
down from the lower auger and configured to mingle whole portions
of meat stored in the hopper.
13. The system of claim 12, wherein the hopper comprises an upper
section and a lower section electrically isolated from the upper
section and is configured to feed whole portions of meat downward
toward the lower auger; and further comprising a controller
configured to detect an electrical conductivity between the upper
section and the lower section of the hopper and configured to
determine that the upper section of the hopper is empty and to
issue an alarm to reload the upper section of the hopper in
response to a low measured electrical conductivity between the
upper section and the lower section of the hopper.
14. The system of claim 1, further comprising: a set of hoppers,
each hopper in the set of hoppers configured to store whole
portions of meat, defining an outlet configured to couple to an
inlet of the grinder, and comprising a hopper piston opposite the
outlet; a magazine configured to support each hopper in the set of
hoppers and to selectively position each hopper, in the set of
hoppers, in a discharge position to supply whole portions of meat
to the grinder; and a hopper actuator configured to drive a hopper
piston of a hopper in the discharge position toward the grinder to
feed whole portions of meat into the grinder.
15. The system of claim 14, further comprising an intermediate
container; wherein the set of hoppers comprises a first hopper
containing whole portions of meat of a first type and a second
hopper containing whole portions of meat of a second type distinct
from the first type; and wherein, in response to receipt of a food
order specifying meat of the second type when the first hopper is
in the discharge position: the grinder grinds remnants of meat of
the first type contained in the grinder into the intermediate
container; the magazine exchanges the first hopper for the second
hopper; the hopper actuator drives the hopper piston of the second
hopper toward the outlet of the second hopper; and the grinder
grinds whole portions of meat of the second type into the
cylinder.
16. The system of claim 1, wherein: the gas supply comprises a
reservoir containing pressurized gas, a first valve fluidly coupled
to the reservoir and to the cylinder, a first pressure regulator
set to a first pressure and interposed between the reservoir and
the first valve, a second valve fluidly coupled to the reservoir
and to the cylinder, and a second pressure regulator set to a
second pressure and interposed between the reservoir and the second
valve; the second pressure is greater than the first pressure; the
first valve opens for a first duration of time during the grind
cycle; the second valve opens for a second duration of time during
the dispense cycle; and the second duration is less than the first
duration.
17. A method of forming a meat patty comprising: receiving a food
order specifying a meat patty; driving a piston to a load position
within a cylinder, wherein the load position is offset below a top
of the cylinder by a distance corresponding to a specified size of
the meat patty; displacing gas into a chamber in the cylinder
behind the piston at a first pressure, the piston perforated to
release gas from the chamber; positioning the cylinder in a grind
position under a grinder; dispensing a quantity of ground meat from
the grinder into the cylinder during a grind cycle; in response to
a first load on the cylinder in the grind position exceeding a
first threshold load, shifting the cylinder to a weigh position
that is offset from the grinder; and during a dispense cycle, in
response to a second load on the cylinder in the weigh position
exceeding a second threshold load corresponding to a target size of
the meat patty: inverting the cylinder, driving the piston toward
the top of the cylinder, and displacing gas into the chamber at a
second pressure greater than the first pressure to dispense the
quantity of ground meat, in the form of a patty, from the
cylinder.
18. The method of claim 17, further comprising, following the
dispense cycle, recording a third load on the cylinder in the weigh
position and confirming dispensation of the quantity of ground meat
from the cylinder based on the second load exceeding the third
load.
19. The method of claim 17, wherein receiving the food order
comprises receiving a custom food order specifying a doneness level
for the meat patty; and wherein shifting the cylinder to the weigh
position in response to the first load on the cylinder in the grind
position exceeding the first threshold load comprises shifting the
cylinder to the weigh position in response to the first load on the
cylinder in the grind position exceeding the first threshold load
corresponding to a preset compaction level of ground meat in the
cylinder for the doneness level specified in the custom food
order.
20. The method of claim 17, further comprising, in response to the
second threshold load corresponding to the target size of the meat
patty exceeding the second load on the cylinder in the weigh
position: calculating an adjusted first threshold load on the
cylinder in the grind position based on a difference between the
second load and the second threshold load; returning the cylinder
to the grind position; dispensing additional ground meat from the
grinder into the cylinder; in response to a third load on the
cylinder in the grind position exceeding the adjusted first
threshold load, shifting the cylinder to the weigh position;
executing the dispense cycle in response to a fourth load on the
cylinder in the weigh position exceeding the second threshold load;
and storing the adjusted first threshold load for implementation in
a subsequent grind cycle for a subsequent meat patty.
Description
[0001] This application claims the benefit of U.S. Provisional
Application No. 62/162,796, filed on 17, May 2015, which is
incorporated in its entirety by this reference.
[0002] This application is related to U.S. patent application Ser.
No. 14/208,149, filed on 13 Mar. 2014, U.S. patent application Ser.
No. 14/534,038, filed on 05, Nov. 2014, and U.S. patent application
Ser. No. 13/911,637, filed on 06, Jun. 2013, all of which are
incorporated in their entireties by this reference.
TECHNICAL FIELD
[0003] This invention relates generally to the field of food
preparation and more specifically to a new and useful system and
method for grinding a meat patty in the field of food
preparation.
BRIEF DESCRIPTION OF THE FIGURES
[0004] FIGS. 1A and 1B are a schematic representations of a
system;
[0005] FIG. 2 is a schematic representation of one variation of the
system;
[0006] FIG. 3 is a schematic representation of one variation of the
system;
[0007] FIG. 4 is a schematic representation of one variation of the
system;
[0008] FIG. 5 is a schematic representation of one variation of the
system;
[0009] FIG. 6 is a schematic representation of one variation of the
system;
[0010] FIG. 7 is a schematic representation of one variation of the
system;
[0011] FIG. 8 is a schematic representation of one variation of the
system;
[0012] FIG. 9 is a schematic representation of one variation of the
system;
[0013] FIG. 10 is a flowchart representation of a method; and
[0014] FIG. 11 is a flowchart representation of one variation of
the method.
DESCRIPTION OF THE EMBODIMENTS
[0015] The following description of the embodiments of the
invention is not intended to limit the invention to these
embodiments but rather to enable a person skilled in the art to
make and use this invention.
1. System
[0016] As shown in FIGS. 1A and 1B, a system 100 for grinding a
meat patty includes: a cylinder 110 defining a cylindrical internal
wall; a piston 120 sliding within the cylinder 110 and including a
scraper engaging the cylindrical internal wall of the cylinder 110;
an actuator system 140 selectively inverting the cylinder 110 and
driving the piston 120 to an initial position within the cylinder
110; a hopper configured to receive whole portions of meat; a
grinder 130 receiving whole portions of meat from the hopper,
grinding whole portions of meat, and dispensing ground meat into
the cylinder 110 in a grind position to drive the piston 120 from
the initial position toward a target position; an arm selectively
displacing the cylinder 110 between the grind position and a
dispense position adjacent a cooking surface; and a controller 160.
The controller 160: disables the grinder 130 and triggers the arm
to displace the cylinder 110 from the grind position to the
dispense position in response to displacement of the piston 120
from the initial position to the target position; triggers the
actuator system 140 to invert the cylinder 110 in the dispense
position; and triggers the actuator system 140 to drive the piston
120 toward the initial position (at the top of the cylinder) to
discard a mass of ground meat from the cylinder 110 onto the
cooking surface.
[0017] One variation of the system 100 includes: a cylinder 110
operable in an upright position and an inverted position; a piston
120 running within the cylinder 110 and defining a set of gas ports
122; a grinder 130 configured to grind meat and to dispense a
quantity of ground meat onto the piston 120 in the cylinder 110
during a grind cycle, the cylinder 110 in the upright position
during the grind cycle; an actuator system 140 configured to
transition the cylinder 110 from the upright position to the
inverted position during a dispense cycle to dispense the quantity
of ground meat in the form of a patty from the cylinder 110; and a
gas supply 150 configured to supply gas to the cylinder 110 behind
the piston 120 at a first pressure during the grind cycle to limit
ingress of ground meat into the gas ports 122 and configured to
supply gas to the cylinder 110 behind the piston 120 at a second
pressure greater than the first pressure during the dispense cycle
to dislodge the quantity of ground meat from the piston 120.
2. Method
[0018] As shown in FIG. 10, a method S100, for grinding a meat
patty includes: driving a piston within a cylinder into an initial
position in Block S120; retracting the cylinder into a grind
position in Block S124; actuating a grinder to dispense a mass of
ground meat into the cylinder in Block S126; in response to
displacement of the piston from the initial position to a target
position by ground meat dispensed from the grinder, disabling the
grinder in Block S130; advancing the cylinder into a dispense
position adjacent a cooking surface in Block S140; inverting the
cylinder in the dispense position in Block S140; and driving the
piston to the initial position (at the top of the cylinder) to
discard the mass of ground meat from the cylinder onto the cooking
surface in Block S142.
[0019] One variation of the method S100 includes: receiving a food
order specifying a meat patty in Block S110; driving a piston to a
load position within a cylinder in Block S120, the load position
offset below a top of the cylinder by a distance corresponding to a
specified size of the meat patty; displacing gas into a chamber in
the cylinder behind the piston at a first pressure, the piston
perforated to release gas from the chamber in Block S122;
positioning the cylinder in a grind position under a grinder in
Block S124; dispensing a quantity of ground meat from the grinder
into the cylinder during a grind cycle in Block S126; in response
to a first load on the cylinder in the grind position exceeding a
first threshold load, shifting the cylinder to a weigh position
offset from the grinder in Block S130. This variation of the method
S100 further includes, during a dispense cycle, in response to a
second load on the cylinder in the weigh position exceeding a
second threshold load corresponding to a target size of the meat
patty: inverting the cylinder in Block S140; driving the piston
toward the top of the cylinder in Block 142; and displacing gas
into the chamber at a second pressure greater than the first
pressure to dispense the quantity of ground meat, in the form of a
patty, from the cylinder in Block S144.
3. Applications
[0020] The system 100 for grinding a meat patty (or the "system")
functions to grind whole portions of raw meat, to dispense at least
a minimum quantity (e.g., mass, weight, or volume) of ground meat
into a cylinder, and to then release the contents of the cylinder
onto an adjacent cooking surface for cooking prior to assembly with
other ingredients into a hamburger. The system 100 can be a
subsystem within an automated foodstuff assembly system 200
including one or more other subsystems to prepare, assemble, and
deliver foodstuffs for and/or to consumers automatically. For
example, the automated foodstuff assembly system 200 can include
the patty grinding subsystem that grinds and presses custom
hamburger patties from raw meat (e.g., based on custom patty
orders), a patty grilling subsystem that grills patties (e.g.,
rare, medium, or well-done patties based on custom patty orders), a
bun dispenser and slicing subsystem that slices buns, a bun
buttering subsystem that applies butter to each side of sliced buns
prior to toasting the halves of the bun, a bun toaster subsystem
that toasts each side of the bun, a topping module that loads
toppings onto bun heels (e.g., based on custom topping orders), a
condiment subsystem that loads condiments onto the bun crown, and a
boxing subsystem that closes completed hamburgers into paper boxes
for delivery to patrons. The system 100 can similarly grind and
press meat patties or veggie patties (e.g., from raw or cooked
vegetables) for assembly into other types of assembled foodstuffs,
such as sandwiches, hotdogs, burritos, tacos, or wraps according to
custom food orders submitted by patrons to a restaurant housing an
automated foodstuff assembly system 200. The system 100 can
therefore be incorporated into an automated foodstuff assembly
system 200 to grind and press meat (or veggie) patties from raw
ingredients once an order for a hamburger (or other foodstuff) is
submitted by a patron and in real-time as the patron's order is
being fulfilled.
[0021] Generally, the system 100 implements Blocks of the method
S100 in order to compensate for natural variability of density and
composition (e.g., ratio of fat to protein) of meat to produce
freshly-ground hamburger patties of at least a minimum weight or
mass. In particular, upon conclusion of a grind cycle, the system
100 can weigh a quantity of ground meat dispensed into the
cylinder, return the cylinder to a grind position to receive
additional ground meat from the grinder if a minimum weight or mass
is not met, and feed the weight of and the grind parameters for the
quantity of ground meat forward to a next grind cycle in order to
compensate for variations in meat density and composition when
grinding and forming a next hamburger patty. For example, by
calculating a running or weighted averaging of the weight of ground
meat dispensed into the cylinder per unit of grind time (or per
unit deflection of the cylinder, per unit displacement of the
piston, etc. as described below) for a most recent set of (e.g.,
ten) hamburger patties formed by the system 100 following
completion of each hamburger patty, the system 100 can calculate a
grind duration (or a target deflection of the cylinder, a target
displacement of the piston, etc.) to achieve a target weight of
ground meat in a subsequent grind cycle with no underage and
minimal overage from the target weight despite global variations in
the density and composition of a mass of whole portions of meat
loaded into the system 100.
[0022] The system 100 can also implement Blocks of the method S100
to grind and press hamburger patties of a particular density. In
particular, the system 100 can grind a particular mass of meat into
the cylinder, and the system 100 can compress this mass of meat
into a hamburger patty of a particular volume yielding a density
corresponding to a particular target compaction level. For example,
to produce a raw hamburger patty suited to a well-done doneness
level, the system 100 can grind and press a quantity of meat into a
relatively short hamburger patty corresponding to a high level of
compaction, thereby reducing a thermal distance between the center
of the hamburger patty and its top and bottom surfaces and yielding
a higher center temperature in the cooked hamburger patty for a
given cook time and heat flux. In this example, to produce a raw
hamburger patty of the same raw weight suited to a rare doneness
level, the system 100 can grind and press a quantity of meat into a
relatively tall hamburger patty corresponding to a low level of
compaction, thereby increasing a thermal distance between the
center of the hamburger patty and its top and bottom surfaces and
yielding a lower center temperature in the cooked hamburger patty
for the same cook time and heat flux. The system 100 can thus
control a density (or level of compaction) of a quantity of ground
meat dispensed into the cylinder based on a doneness level
specified for the hamburger patty in a corresponding food
order.
[0023] Furthermore, the system 100 can include a gas supply 150
that supplies a burst of air between the piston and a quantity of
ground meat during a dispense cycle in order to dislodge the
quantity of ground meat--in the form of a hamburger patty--from the
cylinder. However, because the grinder may dispense meat into the
cylinder at a relatively high pressure, the gas supply 150 can also
maintain gas pressure behind the piston (or maintain a positive
flow rate of gas past the piston) during a grind cycle in order to
prevent or limit ingress of food material (e.g., ground meat,
fluids) past the piston, which may otherwise spoil, interfere with
motion of the piston, and/or necessitate more frequent or deeper
cleaning between operating periods of the system 100.
[0024] The system 100 is described herein as a system for grinding
whole portions of raw meat into ground hamburger patties. However,
the system 100 can additionally or alternatively grind vegetables,
fish, cooked or uncooked sausage, and/or any other raw,
semi-cooked, or cooked ingredients into round patties, rectangular
patties, or patties of any other geometry and can dispense a patty
onto any other cooking surface, heating surface, bun, salad, or
other container or surface.
4. Automated Food Assembly Apparatus
[0025] The system 100 can function as a subsystem within an
automated foodstuff assembly apparatus including one or more other
subsystems that automatically prepare, assemble, and deliver
foodstuffs according to custom food orders submitted by local
and/or remote patrons. For example, the automated foodstuff
assembly apparatus can include: a bun dispenser and slicing
subsystem that slices and dispenses a bun from a bun hopper; a bun
buttering subsystem that applies butter to each side of the sliced
bun prior to toasting the halves of the bun; a bun toaster
subsystem that toasts each side of the bun; a topping module that
loads a custom set of toppings in custom quantities onto the bun
heel according to topping specifications in a custom food order
received from a patron; a condiment subsystem that loads condiments
onto the bun crown according to condiment specifications in the
custom food order; the system 100 is a patty grinding system that
grinds a quantity of raw meat (e.g., based on a custom patty size
and a custom meat blend specified in the custom food order) and
that presses this quantity of meat into a custom hamburger patty
(e.g., to a compression level corresponding to a custom doneness
level specified in the custom food order); a patty cooking
subsystem that cooks the hamburger patty received from the patty
grinding system according to the custom doneness level specified in
the custom food order and dispenses the cooked hamburger patty onto
the bun heel; and a boxing subsystem that closes the completed
hamburger within a paper box for subsequent delivery to the
corresponding patron.
[0026] The system 100 can grind and press hamburger patties (or
veggie patties) from whole portions of raw meat (or from raw or
cooked vegetables) and dispense these hamburger patties onto a
cooking surface or into a cooking system. Once cooked, a hamburger
patty ground and pressed by the system 100 can be combined with
other ingredients to assemble a hamburger, a sandwich, a hotdog, a
burrito, a taco, a salad, or a wrap, etc. according to a custom
food order submitted by a patron to a restaurant, food truck,
convenience store, grocery store, or food kiosk, etc. housing such
as an automated foodstuff assembly apparatus. The system 100 can
therefore be incorporated into an automated foodstuff assembly
apparatus to automatically grind and press raw hamburger patties
for immediate cooking, assembly into a hamburger (or other
foodstuff), and delivery to a patron following submission of a
custom food order by the patron.
5. Food Order
[0027] As shown in FIGS. 10 and 11, Block S110 of the method S100
recites receiving a food order specifying a meat patty. Generally,
the system 100 functions to receive an order for a raw hamburger
patty in Block S110 and then executes the subsequent Blocks of the
method S100 to produce a raw hamburger patty according to the food
order.
[0028] In one implementation, upon receipt of a hamburger order,
the automated foodstuff assembly apparatus passes a request for a
generic hamburger patty of a preset size (e.g., 100 grams+10
grams/-0 grams), of a preset doneness value (e.g., medium-well),
and/or of a preset density or compaction level (e.g., 30 pounds per
cubic foot) to the system 100; the system 100 thus receives this
request for a generic hamburger patty in Block S110 and executes
subsequent Blocks of the method S100 as described below to fulfill
the request.
[0029] In another implementation, a patron can generate a hamburger
order within an ordering interface executing on a mobile computing
device (e.g., a smartphone) or at a local kiosk connected to the
automated foodstuff assembly apparatus. Within the ordering
interface, the patron can select a radio button corresponding to
hamburger patty size (e.g., small (three ounces), medium (five
ounces), or large (eight ounces) and manipulate a slider along a
slider bar to select a doneness value for the hamburger patty in
the patron's hamburger order, such as a quantitative doneness value
between 1 and 100 along a 100-increment slider bar. Upon receipt of
this hamburger order, the automated foodstuff assembly apparatus
can distribute a request for a new hamburger patty--of the size and
cooked to the doneness value specified in the food order--to the
system 100 (e.g., to a controller 160) in Block S110, and the
system 100 can calculate a load position for the piston, a grind
duration for the grinder, and/or a deflection distance for the
cylinder, etc., as described below, for a grind cycle to form a raw
hamburger patty according to specifications defined in the new food
order. However, the system 100 can receive an order, command, or
request for a new hamburger patty in any other way and including
any other specifications in Block S110.
6. Housing
[0030] As shown in FIGS. 1A and 1B, one variation of the patty
grinding system includes a housing 190 that defines an enclosed
volume configured to house the hopper and the grinder. The housing
190 can include two doors, including a first door arranged over the
hopper and manually operable by an operator to dispense whole
portions of raw meat into the hopper below, and including a second
door 192 adjacent the arm and automatically operable by a door
actuator or directly by the arm as the arm moves the cylinder (with
fresh-ground patty) from the grind position within the housing 190
to the dispense position adjacent a cooking surface external the
housing 190. The housing 190 can also include a funnel adjacent or
extending from the upper door toward the hopper to guide whole
portions of meat loaded through the upper door into the hopper
below.
[0031] In one implementation, the system 100 includes a
refrigeration unit 194 arranged within the housing 190. For
example, the automated food assembly apparatus (including the
system 100 can include a remote compressor, and the system 100 can
include a single evaporator arranged within the housing 190 and
coupled to the remote compressor by refrigerant supply and return
lines, as shown in FIG. 1A. In this example, the evaporator can
define a thin rectangular structure of large surface area and can
be arranged within the housing 190 adjacent and facing the hopper.
Alternatively, the system 100 can include an evaporator integrated
into the hopper or integrated into the grinder to cool these
components directly. In this variation, the housing 190 can also
include internal baffles near its doors (described above) to reduce
air mixing release of cooled air from the housing 190 when fresh
whole portions of meat are loaded into the hopper through the upper
door and when the arm drives the cylinder from the grind position,
through the side door 192, to the dispense position.
7. Hopper
[0032] As shown in FIGS. 1A and 1B, one variation of the system 100
includes a hopper configured to store whole portions of meat.
Generally, the hopper defines a container configured to store whole
portions of meat and to dispense whole portions of meat into an
inlet of the grinder. As described above, the hopper can be
arranged within the housing with an open end supported below the
upper door of the housing to collect whole portions of meat
dispensed through the upper door, as shown in FIG. 1B.
[0033] The hopper can also include one or more augers configured to
mingle (or "mix") whole portions of meat--such as in the form of
approximately one-inch-cubed cubes of beef, bison, chicken, or
turkey--within the hopper and to drive whole portions of meat from
the hopper toward the inlet of the grinder. In one example, the
hopper includes an upper auger and a lower auger, wherein the upper
auger defines a double-helical beater that mixes whole portions of
meat in the hopper, and wherein the lower auger (arranged below the
upper auger) defines a screw that drives whole portions of meat
laterally toward the grinder, as shown in FIG. 2. The upper and
lower augers can be geared together by a gearbox and driven by a
single motor, and the gearbox and motor can be isolated from a food
contact zone within the housing, as shown in FIG. 3.
[0034] In one implementation, the gearbox includes two output
shafts terminating at quick-release couplers that transiently
engage corresponding input shafts of the upper and lower augers. In
this implementation, the gearbox and motor can be substantially
intransiently installed within the housing, and the hopper and
upper and lower augers can be removed from the housing in-unit,
disassembled, and cleaned--such as by hand or in a
dishwasher--between periods of operation. For example, the hopper
can be constrained within the housing by quick-release locks (as
shown in FIG. 3) and the motor and gearbox can be supported on a
linear tack aligned with the axes of the input shafts of the augers
such that an operator can slide the motor and gearbox along the
linear track to separate the flexible, quick release couplers of
the gearbox from the input shafts of the augers, release the
quick-release locks on the hopper, pivot the hopper from a support
stand within the housing, and remove the hopper and upper and
lower-augers in-unit.
[0035] The hopper can be intermittently loaded with whole portions
of pre-seasoned meat by an (human) operator. Alternatively, the
system 100 can include a seasoning module arranged within or
external the housing, and the seasoning module can dispense
seasonings (e.g., salt, pepper, garlic powder) onto an exposed
surface of a patty once meat is ground into the cylinder, such as
at an intermediate seasoning position between the grind position
adjacent the grinder and the dispense position adjacent an external
cooking surface. The seasoning module can also dispense seasonings
into the cylinder following a dispense cycle and prior to a next
grind cycle (i.e., when the cylinder is substantially empty) such
that the bottom surface of the next hamburger patty thus formed is
also coated with a seasoning, and the seasoning module can dispense
additional seasoning onto the top of the hamburger patty, such as
once the quantity of ground meat is confirmed in a subsequent weigh
cycle and before the hamburger patty is dispensed in a dispense
cycle. Alternatively, the grinder can dispense a sublayer of ground
meat into the cylinder, the actuator system can move the cylinder
to an intermediate seasoning position, the seasoning module can
dispense seasonings onto the sublayer of ground meat, the actuator
system can return the cylinder to the grind position, the grinder
can dispense another sublayer of ground meat into the cylinder and
over the layer of seasoning, and the system 100 can repeat this
process to form a single patty with multiple layers of ground meat
and seasoning before weighing the quantity of ground meat in the
cylinder and dispensing the patty onto an adjacent cooking surface.
Yet alternatively, the seasoning module can dispense a controlled
amount (e.g., mass, weight, volume) of seasonings directly into the
hopper, into a feed tube between the hopper and the grinder, or
directly into the grinder as the grinder grinds whole portions of
meat into the cylinder.
[0036] In one implementation, the hopper includes an upper section
and a lower section electrically isolated from the upper section
and is configured to feed whole portions of meat downward toward
the lower auger, as shown in FIG. 3. In this implementation, the
system 100 (e.g., the controller 160 described below) can monitor
electrical conductivity between the upper section of the hopper and
the lower section of the hopper. Because raw portions of meat may
conduct electricity, the system 100 can determine that the upper
section of the hopper is empty if no electrical conductivity or low
electrical conductivity is measured across the upper section and
the lower section of the hopper, and the system 100 can then issue
an alarm or other prompt to reload the upper section of the hopper.
For example, when fully loaded with portions of meat, the upper
section of the hopper can store a mass of meat sufficient to form
100 hamburger patties, and the lower section of the hopper can
store a mass of meat sufficient to form 50 hamburger patties. In
this example, when electrical contact between the upper and lower
sections of the hopper is lost, the system 100 can determine that
the hopper contains a mass of meat sufficient for approximately 50
hamburgers. The system 100 can then maintain a counter of hamburger
patties subsequently formed and transmit a notification to an
operator's mobile computing device to reload the hopper once the
estimated mass of meat remaining in the hopper is sufficient for
fewer than 20 hamburger patties. The system 100 can additionally or
alternatively issue an audible or visible alarm on the automated
foodstuff assembly apparatus to reload the hopper. Alternatively,
the system 100 can track an amount of meat in the hopper based on a
weight of the hopper, a weight of the housing, an output of a
distance sensor arranged over the hopper, or in any other way or
based on any other sensor output, and the system 100 can prompt an
operator to reload the hopper in any other way and at any other
suitable time during operation.
8. Grinder
[0037] As shown in FIGS. 2 and 3, the grinder 130 is configured to
grind meat and to dispense a quantity of ground meat onto the
piston in the cylinder during a grind cycle. Generally, the grinder
130 functions to receive whole portions of meat from the hopper, to
grind these whole portions of meat, and to dispense ground meat
into the cylinder supported in the grind position by the actuator
system.
[0038] In one implementation, the grinder 130 includes a (vertical)
grinding screw configured to drive whole portions of meat--received
from the hopper via the lower auger--through a die and into the
cylinder (in the grind position) below, as shown in FIG. 4. In this
implementation, the grinding screw can be driven by a motor via a
gearbox and a quick-release coupler, and the motor and gearbox of
the grinder 130 can be mounted substantially intransiently within
or on the housing and isolated from the food contact zone within
the housing. Like the hopper, the grinder 130 can be constrained
within the housing by one or more quick-release locks (as shown in
FIGS. 3 and 4) that can be released by an operator to remove the
grinder 130 (e.g., grinding head, die, and grinding screw) from the
housing. The grinder 130 can then be disassembled and cleaned--such
as manually or in a dishwasher--between periods of operation.
[0039] However, the grinder 130 can be of any other type and can
operate in any other way to grind or "mince" meat fed from the
hopper and to deposit such ground or "minced" meat into the
cylinder below (or beside) the outlet of the grinder 130.
9. Cylinder, Piston, and Actuator System
[0040] As shown in FIGS. 4, 5, 6, and 7, the system also includes:
a cylinder 110 operable in a upright position and an inverted
position; a piston 120 running within the cylinder 110 and defining
a set of gas ports 122; and an actuator system 140 configured to
transition the cylinder 110 from the upright position to the
inverted position during a dispense cycle to dispense the quantity
of ground meat in the form of a patty from the cylinder 110.
Generally, the cylinder 110 can define a cylindrical internal wall;
the piston 120 can slide within the cylinder 110 and can include a
scraper that engages the cylindrical internal wall of the cylinder
110 to remove ground meat and other debris from the internal wall;
and the actuator system 140 can selectively invert the cylinder 110
between upright and inverted positions, can selectively drive the
piston 120 between a load position offset below the top of the
cylinder 110 to receive ground meat from the grinder and an unload
position proximal a top of the cylinder 110 to force a hamburger
patty out of the cylinder 110, and can selectively position the
cylinder 110 between a grind position and an dispense position.
[0041] As shown in FIG. 5, the cylinder 110 can define a
cylindrical internal volume (i.e., an internal volume of constant
circular cross-section) open on both ends. For example, the
cylinder no can include a Teflon-coated aluminum cylinder no or an
ultra-high-molecular-weight polyethylene cylinder no. However, the
cylinder no can define any other geometry and can be constructed of
any other suitable material or combination of materials. The
actuation system can include an arm (or beam, or boom); the
cylinder 110 can be supported on a distal end of the arm, as
described below, and can be driven between an upright position to
receive ground meat from the grinder and an inverted position to
dispense a patty onto an adjacent cooking surface by the actuator
system 140. For example, the cylinder no can be hung on a first
shaft pivotably mounted on the distal end of the arm substantially
perpendicular to the central axis of the cylinder no, and the
cylinder no can thus pivot about the axis of the first shaft
between the upright and inverted positions, as shown in FIG. 5.
[0042] As shown in FIG. 7, the piston 120 runs along the interior
wall of the cylinder no and can include a scraper, O-ring, and/or
other seal or scraper configured to remove fat and other deposits
from the interior wall of the cylinder 110 as the piston 120 is
driven from the load position to the unload position. The piston
120 also functions to drive a patty out of the cylinder 110 and
onto an adjacent cooking surface as the piston 120 is driven--by
the actuator system 140--from the load position to the unload
position within the cylinder no. For example, the piston 120 can be
coupled by a linkage (e.g., a crank and a connecting rod) to a
second shaft parallel and adjacent the first shaft, as shown in
FIG. 6, wherein the actuator system 140 similarly drives the piston
120 linearly through the cylinder 110 via the second shaft. In one
implementation, the piston 120 defines a smooth, Teflon-coated,
flat surface facing the top of the cylinder 110. In another
implementation, the piston 120 defines a perforated surface facing
the open end of the cylinder 110 to yield a relatively low total
surface area in contact with ground meat across the face of the
piston 120; the gas supply 150 line can be fluidly coupled to the
cylinder no behind the piston 120, and the system 100 can trigger a
valve to release compressed gas into a chamber behind the piston
120; this gas can then travel through perforations in the piston
120 to separate the ground meat from the face of the piston 120
when dispensing the patty onto an adjacent cooking surface, as
described below. However, the piston 120 can define any other
surface geometry.
[0043] The actuator system 140 functions to invert the cylinder 110
between the upright and inverted positions and to drive the piston
120 between the load position and the unload position. In one
implementation, the actuator system 140 includes a primary actuator
141 (e.g., a rotary motor) and a planetary gearbox 145, as shown in
FIGS. 4 and 7. In this implementation, the output shaft of the
primary actuator 141 (e.g., an electric, pneumatic, or hydraulic
motor) can be mechanically coupled to the ring gear of the
planetary gearbox 145, the first shaft (supporting the cylinder no)
can be coupled to the sun gear of the planetary gearbox 145 via a
planet arm, and the second shaft (connected to the piston 120 via
the linkage) can be coupled to the planet gears of the planetary
gearbox 145. The seal and/or scraper arranged about the perimeter
of the piston 120 can yield a mechanical resistance to translation
of the piston 120 within the cylinder 110 (and therefore resistance
to rotation of the second shaft) that exceeds a total mechanical
resistance to rotation of the first shaft and the cylinder no
assembly. Thus, with the cylinder 110 in the upright position and
the piston 120 in the load position, the seal can constrain the
piston 120 in the cylinder no and effectively lock the position of
the planet arm relative to the first shaft such that, when the
primary actuator 141 initially applies a torque to the ring gear,
sun gear, planet gears, and planet arm, rotate in unit, thereby
rotating the first shaft and inverting the cylinder 110 from the
upright position to the inverted position with the piston 120
remaining in the same position within the cylinder 110. However,
once the cylinder 110 reaches the inverted position and contacts an
invert stop, continued application of torque by the primary
actuator 141 into the gearbox 145 can overcome mechanical
resistance between the piston 120 and the cylinder 110 and thus
drive the piston 120 from the load position toward the unload
position. In particular, with the cylinder 110 thus driven against
the invert stop, the sun gear in the planetary gearbox 145 can be
locked against further rotation as the ring gear continues to
rotate under torque applied by the primary actuator 141, and the
planet gears and the planet arm can thus rotate (at some ratio of
rotation) about the sun gear, thereby rotating the second shaft
relative to the first shaft and driving the piston 120 toward the
unload position within the cylinder 110. For example, with the arm
supporting the cylinder 110 in the upright position over a cooking
surface and with a metered quantity of ground meat loaded in the
cylinder 110, the primary actuator 141 can drive the planetary
gearbox 145 to first invert the cylinder 110 in Block S140 and to
then drive the piston 120 from the load position within the
cylinder 110 to the unload position within the cylinder 110 in
Block S142, thereby forcing the patty out of the cylinder 110 and
onto the cooking surface.
[0044] Once the patty is thus released from the cylinder 110 and
the piston 120 reaches the unload position, the primary actuator
141 can reverse. However, resistance between the piston 120 and the
inner wall of the cylinder 110 can persist such that the first and
second shafts are effectively locked together, thereby causing the
first shaft to rotate and the cylinder 110 to return to the upright
position with the piston 120 remaining in the unload position as
the primary actuator 141 rotates in the reverse direction. When the
cylinder 110 returns to the upright position and contacts an
upright stop, the primary actuator 141 can cease rotation, and the
arm can return the cylinder 110 to the grind position adjacent the
grinder where a receiver adjacent the output of the grinder
constrains the cylinder 110. When the grinder subsequently outputs
ground meat into the cylinder 110, the ground meat can force the
piston 120 from the unload position downward toward the load
position, thereby rotating the second shaft, the planet gears, the
ring gear, and the output shaft of the primary actuator 141, as
described below.
[0045] Alternatively, with the cylinder 110 in the dispense
position, returned to the upright position, and constrained against
further rotation in the reverse direction by an upright stop, the
sun gear in the planetary gearbox 145 can cease rotation, and the
planet gears and planet arm can rotate with the ring gear as the
primary actuator 141 continues to reverse direction, thereby
rotating the second shaft and retracting the piston 120 toward the
load position, as described below.
[0046] As described below, the system 100 can include a controller
160 (shown in FIG. 1A) that intermittently sets forward and reverse
speeds of the primary actuator 141 based on the position of
cylinder 110 and/or the position of the piston 120 within the
cylinder 110. In one example, the controller 160 monitors torque
output of the primary actuator 141 to determine the position of the
cylinder 110 and/or the piston 120. In this example, for the
cylinder 110 initially in the upright position and the piston 120
initially in the load position at the beginning of a dispense
cycle, the controller 160 can correlate a first near-step increase
in torque output of the primary actuator 141 with the cylinder 110
hitting the invert stop in Block S140, and the controller 160 can
then correlate a subsequent near-step increase in torque output of
the primary actuator 141 with the piston 120 reaching the unload
position and hitting a travel limit in Block S142. In this example,
the controller 160 can also correlate a drop in torque output of
the primary actuator 141 after the first step increase in torque
output and before the second increase in torque output with release
of a patty from the cylinder 110. Similarly, for the cylinder 110
initially in the inverted position and the piston 120 initially in
the unload position with the primary actuator 141 rotating in the
reverse direction, the controller 160 can correlate a first
near-step increase in torque output of the primary actuator 141
with the cylinder no hitting the upright stop, and the controller
160 can thus cease operation of the primary actuator 141 and
trigger the actuation system to retract the cylinder 110 into the
grind position.
[0047] Alternatively, the actuator system 140 can include one or
more binary limit switches, such as one binary limit switch that
changes its output state when the cylinder 110 enters the upright
position, one binary limit switch that changes its output state
when the cylinder 110 enters the inverted position, one binary
limit switch that changes its output state when the piston 120
enters the unload position, and one binary limit switch that
changes its output state when the piston 120 enters the load
position, and the controller 160 can set the speed and rotational
direction of the primary actuator 141 according to outputs of these
limit switches. Yet alternatively, the actuator system 140 can
include one or more encoders coupled to the primary actuator 141,
to the ring gear, to the sun gear, to a planet gear, to the first
shaft, and/or to the second shaft, etc., and the controller 160 can
sample the encoders to determine the positions of the cylinder no
and the piston 120 and can adjust the speed and direction of the
primary actuator 141--coupled to the cylinder 110 and to the piston
120--accordingly during a dispense cycle in Blocks S140 and
S142.
[0048] The primary actuator 141 can include a servo motor, a
stepper motor, a rotary pneumatic actuator, a rotary hydraulic
actuator, or any other type of actuator suitable to drive the
cylinder 110 between the upright and inverted positions and to
drive the piston 120 between the load and unload positions. The
actuator system 140 can also include multiple actuators, such as
one electric motor that transitions the cylinder 110 between the
upright position and the inverted position independent of a second
electric motor that transitions the piston 120 between the load
position and the unload position. The actuator(s) of the actuator
system 140 can be supported on the arm, such as adjacent the
cylinder 110. Alternatively, the actuator(s) of the actuator system
140 can be remote from the cylinder 110, such as mounted on the
exterior of the housing and coupled to the cylinder 110 and the
piston 120 via one or more flexible cables.
[0049] However, the cylinder 110, the piston 120, and the actuator
system 140 can be of any other form and can function in any other
way to receive a quantity of ground meat during a grind cycle in
Block S126 and to unload a hamburger patty during a dispense cycle
in Blocks S140 and S142.
10. Arm
[0050] As described above, the system 100 can further include an
arm 144 that supports the cylinder, and the actuation system can
manipulate the arm 144 to selectively displace the cylinder between
the grind position adjacent the grinder and the dispense position
adjacent a cooking surface. Generally, the arm 144 functions to
support the cylinder on its distal end in both the grind position
to receive ground meat during a grind cycle and in the dispense
position to release ground meat--in the form of a hamburger patty
onto an adjacent cooking surface external the housing--during a
dispense cycle.
[0051] The actuation system can further include a secondary
actuator 142, such as a rotary or linear motor, configured to
rotate, extend, or retract the arm 144 from the grind position to
the dispense position and vice versa. For example, the secondary
actuator 142 can include a servo motor, including an absolute
encoder, and the proximal end of the arm 144--opposite the
cylinder--can be mounted to an output shaft of the secondary
actuator 142; when actuated, the second motor can thus pivot the
arm 144 to move the cylinder between the grind and dispense
positions.
[0052] In the foregoing implementation, the arm 144 sweeps the
cylinder along an arc between the grind position and the dispense
position. In this implementation, the arm 144 can pivot a proximal
end opposite the cylinder and can be driven by a rotary actuator
coupled to the proximal end of the arm 144 by a shaft. An (optical)
encoder can be directly coupled to the shaft or driven off the
shaft by a clutched or sprung coupling. In this implementation, the
arm 144 can also include a counterweight--opposite the cylinder
from the shaft--that compensates for the weight of the cylinder and
the actuator system. In this implementation, the side door 192 can
be hinged from the housing, and the arm 144 can pivot the side door
192 open when transitioning the cylinder from the grind position to
the dispense position. Alternatively, the side door 192 can be
coupled to the arm 144 and seal against the housing when the arm
144 is in the grind position, and the door 192 can separate from
the housing as the arm 144 pivots into the dispense position.
[0053] In another implementation, the arm 144 shuttles the cylinder
linearly from the load position, through the side door 192 of the
housing, and into the dispense position adjacent an external
cooking surface. In this implementation, the arm 144 can include a
linear slide that supports the cylinder (and the primary actuator),
and the secondary actuator 142 can include a linear actuator that
extends and retracts the linear slide between the grind and
dispense positions.
11. Load Sensor
[0054] In one variation, the system 100 further includes a load
sensor 162 configured to output a signal corresponding to a mass or
weight of contents in the cylinder. The system 100 can sample the
load sensor 162 during a weigh cycle, described below, to confirm
that at least a threshold amount of ground meat has been loaded
into the cylinder prior to a dispense cycle. The system 100 can
additionally or alternatively sample the load sensor 162 during a
grind cycle to track deflection of the cylinder away from the
outlet of the grinder, which may then be correlated with a complete
loading of the cylinder and/or a level of compaction or density of
ground meat in the cylinder, as described below.
[0055] In one implementation, the cylinder, piston, and primary
actuator are constructed in a cylinder assembly hinged to the
distal end of the arm, and the system 100 further includes a load
cell arranged between the distal end of the arm and the cylinder
assembly and defining a pivot stop for the cylinder assembly. In
this implementation, the weight of the cylinder assembly and the
contents of the cylinder can compress the load cell, and the load
cell can thus output a signal corresponding to this weight of the
cylinder assembly and its contents. In a similar implementation,
the arm can include a post extending vertically from its distal
end, the load cell can be mounted to the distal end of the arm
adjacent the post, and the cylinder assembly can include a linear
slide that accepts and slides vertically along the post and can
rest on the load cell; the load cell can thus output a signal
corresponding to the weight of the cylinder assembly and its
contents.
[0056] In another implementation, the arm defines a cantilevered
beam, the cylinder assembly is mounted to the distal end of the
cantilevered beam, and the load sensor 162 includes a strain gauge
arranged on the beam, as shown in FIGS. 2 and 3. The controller can
thus sample the load sensor 162 to determine an amount (e.g., a
mass, a weight) of ground meat contained in the cylinder following
a grind cycle.
[0057] In the variation described below in which the system 100
confirms completion of a grind cycle based on deflection of the
arm, the load sensor 162 can exhibit a relatively wide dynamic
range. For example, the load sensor 162 can exhibit a resolution of
approximately one-tenth gram over a range of 50 grams to 250 grams
of mass loaded into the cylinder. In this example, the load sensor
162 can also exhibit a resolution of approximately 5 grams over a
range of 5000 grams to 10,000 grams of load applied by the grinder
to the cylinder as the grinder dispenses ground meat into the
cylinder during a grind cycle. The system 100 (e.g., the
controller) can thus sample the single load cell during a grind
cycle and a subsequent dispense cycle to confirm completion of a
grind cycle and to confirm sufficient loading of the cylinder with
ground meat, respectively. Alternatively, in this variation, the
system 100 can include multiple load sensor 162s, such as
including: a strain gauge arranged along the arm and exhibiting a
dynamic range sufficient to track deflection of the arm during a
grind cycle; and a load cell arranged between the distal end of the
arm and the cylinder assembly and exhibiting a dynamic range
sufficient to weigh the cylinder when the cylinder is arranged in a
weigh position offset from the grinder during a weigh cycle.
However, the system 100 can include any other number and type of
load sensors arranged in any other way.
12. Shear Assembly
[0058] One variation of the system 100 further includes a shear
assembly 170 interposed between the outlet of the grinder and the
rim top of the cylinder (in the grind position), operable between a
retracted position and an advanced position, and configured to
transition from the retracted position to the advanced position
following actuation of the grinder during a grind cycle to separate
a quantity of ground meat dispensed into the cylinder from ground
meat remaining across the outlet of the grinder.
[0059] In one implementation, the shear assembly 170 includes: a
shear plate; and a linear actuator configured to drive a leading
edge of the shear plate across the outlet of the grinder to sever
ground meat in the cylinder from the grinder and configured to
retract the shear plate prior to a next grind cycle to enable the
cylinder to again be loaded with ground meat. In this
implementation, the actuator can retract the shear plate to permit
ground meat to pass from the grinder into the cylinder below, and
the shear actuator can advance the shear plate into the advanced
position between the cylinder and the grinder to sever ground meat
in the cylinder from ground meat at the output of the grinder prior
to actuation of the secondary actuator to move the cylinder from
the grind position to the weigh position. The leading edge of the
shear assembly 170 can include a straight, elliptical, or
semicirclular blade with a straight or serrated profile, and the
shear actuator can rapidly advance the shear plate into the
advanced position to separate the contents of the cylinder and the
contents of the grinder. In one example, the shear assembly
includes a blade that defines a concave semicircular leading edge
of radius equal to the internal radius of the cylinder. In this
example, this profile of the blade can enable the blade to cleanly
shear ground meat from the outlet of the grinder with the leading
edge of the blade pushing a minimal amount of ground meat out of
the cup. The leading edge of the blade can also define a single
bevel facing the cup such that a planar surface of the blade and
its leading edge--facing the outlet of the grinder--contact the
grinder when actuated to yield relatively smooth operation of the
shear assembly and cleaner shearing of ground meat from the
grinder. Furthermore, the blade can extend laterally beyond the
width of outlet of the grinder and beyond the inlet of the cup such
that the blade, when actuated does not catch on an edge of the
grinder or cup throughout its range of motion
[0060] Alternatively, the shear assembly 170 can include a rotary
meat-slicing blade and an actuator configured to pass the rotary
meat-slicing blade through a gap between the outlet of the grinder
and the cylinder while the rotary meat-slicing blade rotates. Yet
alternatively, the shear assembly 170 can include a hot wire and an
actuator configured to pass the hot wire through the gap between
the outlet of the grinder and the cylinder as current passing
through the hot wire heats the hot wire. However, the shear
assembly 170 can include any other structure and actuator
configured to separate ground meat dispensed into the cylinder from
meat remaining in the grinder.
13. Grind Cycle and Weigh Cycle
[0061] Block S124 of the method S100 recites positioning the
cylinder in a grind position under a grinder; Block S126 of the
method S100 recites dispensing a quantity of ground meat from the
grinder into the cylinder during a grind cycle; and Block S130 of
the method S100 recites, in response to a first load on the
cylinder in the grind position exceeding a first threshold load,
shifting the cylinder to a weigh position offset from the grinder.
Generally, the system 100: positions the cylinder under (or
adjacent) the outlet of the grinder in preparation to receive
ground meat from the grinder in Block S124; actuates the grinder to
grind whole portions of raw meat received from the hopper and to
dispense this raw ground (or "minced") meat into the cylinder
during a grind cycle; and executes a weigh cycle in Block S130 to
confirm that a sufficient quantity of ground meat was loaded in the
cylinder.
13.1 Piston Displacement as Control
[0062] In one variation, the system 100 further includes a position
sensor 164 configured to output a signal corresponding to a
position of the piston within the cylinder. In this variation, the
actuator system can return the piston to an unload position in
preparation for a next grind cycle, and the grinder can cease
dispensation of ground meat into the cylinder in response to an
output of the position sensor 164 indicating displacement of the
piston downward to a load position (or a "target position) by
ground meat dispensed into the cylinder by the grinder. Generally,
in this variation, the system 100 tracks displacement of the piston
within the cylinder due to injection of ground meat into the
cylinder by the grinder and concludes a grind cycle when the piston
reaches a load position corresponding to a target size (e.g.,
weight, mass, volume) of a hamburger patty.
[0063] In this variation, the system 100 can also include a
controller that receives a request for a new hamburger patty (e.g.,
in the form of a food order) in Block S110 and then selectively
actuates various actuators within the system 100 to execute a grind
cycle accordingly in Blocks S124 and S126. In one implementation,
following a previous dispense cycle, the controller triggers the
actuation system to return the cylinder to the grind position in
Block S124 in preparation for a next grind cycle. With the cylinder
now empty and supported in the grind position, the controller
triggers a relay to supply power to the grinder in Block S126 in
response to a call for a new hamburger patty in Block S110. While
in operation, the grinder dispenses ground meat into the cylinder,
which forces the piston downward and away from the outlet of the
grinder, and the controller repeatedly samples the position sensor
164 (e.g., an encoder coupled to the primary actuator or to the
gearbox) to track the position of the piston within the cylinder.
Once the piston reaches a preset or recalculated load position (or
approaches or passes the load position, etc.), the controller
ceases operation of the grinder to cease dispensation of ground
meat into the cylinder and then initiates a weigh cycle.
[0064] In this implementation, the controller can calculate or set
the load position as a target displacement distance of the piston
from the unload position (a target offset distance below the rim of
the cylinder) to achieve a hamburger patty of a target weight,
mass, or volume. For example, the controller can calculate a target
displacement of the piston by ground meat dispensed into the
cylinder based on the known cross-sectional area of the cylinder
and historic densities of ground meat loaded into the cylinder (or
a preset static ground meat density prediction), and then trigger
the grinder to dispense ground meat into the cylinder until the
piston is driven down to this target position during a grind cycle.
In this implementation, the controller can maintain the actuator
system in a deactivated (e.g., unpowered) state and thus allow the
piston, primary actuator, and gearbox or other linkage therebetween
to passively resist deflection by ground meat dispensed into the
cylinder. Once the piston is driven down to this load position and
once the grinder ceases operation, the controller can trigger the
shear assembly to advance the shear plate to separate ground meat
in the cylinder from the ground meat at the outlet of the grinder.
The controller can then trigger the secondary actuator to move the
cylinder from the grind position to a weigh position offset (e.g.,
laterally) from the outlet of the grinder and can sample the
controller 160 to confirm that at least a minimum weight of ground
meat was dispensed into the cylinder in Block S130. In this
implementation, if less than the minimum quantity (e.g., weight) of
ground meat is detected in the cylinder, the controller can trigger
the secondary actuator to return the cylinder to the grind
position, can calculate an adjusted target load position based on a
difference between the actual and target amounts of dispensed
ground meat for the grind cycle, and can trigger the relay to again
supply power to the grinder until sufficient ground meat is
dispensed into the cylinder to drive the piston to the adjusted
target load position.
[0065] The controller can repeat this process to weigh the cylinder
and its contents, calculate an adjusted load position, and add
additional ground meat to the cylinder until the target quantity of
ground meat in the cylinder is achieved.
[0066] In one example, in response to receipt of a request for a
hamburger patty at least 100 grams in mass (i.e., a "target mass")
in Block S110, the controller can set the target load position at
20.0 millimeters offset from the unload position (e.g., at which
the face of the piston is offset 20.0 millimeters below the rim of
the cylinder) based on a known cross-sectional area of the cylinder
and a preset approximate density of the type of meat stored in the
hopper to achieve a quantity of meat between 100 grams and 110
grams in mass when the piston is driven to the load position by
ground meat dispensed into the cylinder. The controller then
actuates the grinder in Block S126 until the piston is displaced
20.0 millimeters from the unload position to the target load
position by ground meat dispensed into the cylinder during the
grind cycle. Upon completion of the grind cycle, the controller
triggers the secondary actuator to shift the cylinder to the weigh
position and samples the controller 160 to record a mass (or
weight) of ground meat in the cylinder. In this example, if the
output of the controller 160 indicates that only 96 grams of meat
is contained in the cylinder following the grind cycle, the
controller: adjusts the target load position to 21.0 mm offset
below the unload position, which corresponds to a new prediction of
100.8 g of ground meat in the cylinder upon realization of the
adjusted load position; triggers the secondary actuator to return
the cylinder to the grind position; and again actuates the grinder
until the piston is driven down to the adjusted load position. The
controller then executes another weigh cycle to weigh the contents
of the cylinder in Block S130. If the controller 160 indicates that
greater than 100 grams of ground meat are contained in the
cylinder, the controller can initiate a dispense cycle in Blocks
S140, S142, and S144 to release the quantity of ground meat--in the
form of a hamburger patty--onto a cooking surface for subsequent
cooking. However, if the controller 160 indicates that less than
100 grams of ground meat are contained in the cylinder, the
controller can repeat the foregoing process until the target
quantity of ground meat is achieved.
[0067] Furthermore, in this implementation, the controller can
record the last adjusted load position to achieve the target
quantity of ground meat and can implement this last adjusted load
position as the first load position in a next grind cycle for a
subsequent order for a hamburger patty of the same weight (or
mass). Similarly, if the actual weight (or mass) of a previous
hamburger patty was (significantly) greater than the target weight
(or mass) for the previous hamburger patty, the controller can also
calculate an adjusted load position for a next hamburger patty that
compensates for this overage in the previous hamburger patty. The
controller can also calculate an average weight (or mass) of ground
meat per unit distance that the piston is displaced across a
sequence of hamburger patties and can calculate a target load
position for a next hamburger patty accordingly. For example, the
system 100 can calculate the average weight of ground meat
dispensed per unit distance of piston displacement for a last ten
hamburger patties formed by the system 100 with the weight of the
most-recent hamburger patty weighted more than the weight of a
previous hamburger patty. The controller can also update a lookup
table or parametric model to reflect the actual weight of ground
meat dispensed per unit of displacement of the piston during the
last grind cycle, as described below. The controller can therefore
implement closed loop feedback controls and/or feed-forward
controls to calculate a target load position--for a next hamburger
patty--that accounts for natural variations in density and
composition of meat to maintain a high initial accuracy of weight
(or mass) of ground meat dispensed into the cylinder for each
subsequent hamburger patty.
13.2 Piston Displacement as Control with Density Control
[0068] In another implementation, the system 100 actively controls
the primary actuator to resist displacement of the piston during a
grind cycle in order to control a pressure within the cylinder as
the grinder discharges ground meat into the cylinder. Generally,
the system 100 can implement methods and techniques to control the
density of a quantity of ground meat, such as to achieve a preset
hamburger patty density or to achieve a hamburger patty density
corresponding to a doneness level specified in a custom food order.
In particular, by actively controlling displacement of the piston
away from the outlet of the grinder during a grind cycle, the
system 100 can force ground meat discharged from the grinder to
compress between the piston and the outlet of the grinder, thereby
reducing voids (e.g., air pockets) within the quantity of dispensed
ground meat and yielding control over the density of this quantity
of ground meat in the cylinder.
[0069] In this implementation, the controller can initiate a grind
cycle with the piston in the unload position at or proximal the top
of the cylinder. Throughout the dispense cycle, the controller can:
monitor the current draw of the primary actuator coupled to the
piston; sample a position sensor 164 (e.g., an optical encoder)
coupled to the primary actuator (or to the piston, to the gearbox);
and transform the current draw of the primary actuator and the
position of the piston within the cylinder into a predicted density
of the quantity of ground meat in the cylinder. For example, the
controller can pass the current draw of the primary actuator and
the position of the piston into a lookup table or into a parametric
model defining a relationship between these current draw, piston
position, and ground meat density for the type of meat currently
loaded into the hopper.
[0070] In a similar example, the controller can calculate a torque
output of the primary actuator based on the current draw of the
primary actuator and then calculate a pressure within the cylinder
based on the torque output of the primary actuator, a gear
reduction between the primary actuator and the piston, the
cross-sectional area of the piston, and the position of the piston
within the cylinder (e.g., given that the torque output by the
primary actuator is transferred into a linear force at the piston
as a function of the position of a crank connecting the same). In
this example, the controller can select a target density of the
hamburger patty based on a doneness level specified for the
hamburger patty, can access or calculate a target pressure within
the cylinder correlated with this target density, and can then
modulate an amount of power supplied to the primary actuator in
order to achieve this target pressure within the cylinder.
[0071] The system 100 can set a target density for the hamburger
patty, such as a general target density or a target density
corresponding to a doneness level specified in a custom food order,
and the controller can implement closed-loop feedback techniques to
control the position of the piston within the cylinder--via the
actuator system--during a grind cycle to achieve this target
density. The controller can thus: set a target amount of resistance
to displacement of the piston by dispensed ground meat (e.g., in
the form of a torque output of the primary actuator or power
supplied to the primary actuator) during a grind cycle based on a
target density of the hamburger patty.
[0072] Throughout the grind cycle, ground meat dispensed into the
cylinder can drive the piston downward, as described above, and the
controller can track an offset distance from the rim of the
cylinder to the face of the piston, such as based on the position
of the primary actuator. The controller can then multiply this
offset distance by a known cross-sectional area of the cylinder and
a predicted density of the ground meat at the current pressure
within the cylinder (such as stored in a lookup table) to predict a
total mass of ground meat in the cylinder. The controller can then
conclude the grind cycle and initiate a weigh cycle once the
calculated total mass of ground meat in the cylinder equals,
exceeds, or falls within a threshold range of the target size
(e.g., target mass) of the hamburger patty.
[0073] During the weigh cycle, the controller can: calculate a
swept volume of the piston based on a known cross-sectional area of
the cylinder and the final position of the piston in the cylinder
upon conclusion of the grind cycle; and calculate an actual density
of the quantity of ground meat based on the actual mass (or weight)
of ground meat in the cylinder and the swept volume of the
cylinder; calculate an adjusted target motor current draw or
adjusted target motor output torque to achieve the target density
of ground meat in the cylinder based on the difference between
actual and target densities for the ground meat; and update a
lookup table or parametric model linking motor current draw or
motor output torque to density of ground meat loaded into the
cylinder. If the actual density of the quantity of ground meat is
less than a threshold density but the total mass (or weight) of
ground meat in the cylinder is greater than a threshold quantity,
the controller can return the cylinder to the grind position,
advance the shear assembly, and trigger the primary actuator to
rack the piston to the adjusted target motor current draw or to the
adjusted target motor output torque in order to compress the
quantity of meat between the piston and the shear plate, as
described below. However, if the total mass (or weight) of the
quantity of meat is less than the threshold quantity, the
controller can trigger the secondary actuator to return the
cylinder to the grind position and can actuate the grinder until an
adjusted target load position--described above--is achieved at the
adjusted target motor current draw or motor output torque. The
controller can repeat this process until at least the target
quantity of ground meat is determined to have been
dispensed--within a threshold density range--into the cylinder
before executing a dispense cycle. Otherwise, if the result of the
weigh cycle indicates that more than the target quantity of ground
meat was dispensed into the cylinder at a density greater than a
threshold density, the controller can initiate a dispense
cycle.
13.3 Time as Control
[0074] In another implementation, upon receipt of a request for a
hamburger patty in Block S110, the controller calculates a load
position for the piston based on a known cross-sectional area of
the cylinder, a last measured density (or an average density, a
preset predicted density) of ground meat output by the grinder, and
a size of the hamburger patty specified in the request, as shown in
FIG. 11. The controller can also estimate a grind duration based on
the size (e.g., a target mass) of the hamburger patty and a last
measured mass flow rate (or an average mass flow rate, a preset
predicted mass flow rate) of ground meat from the grinder. In this
implementation, the actuator system returns the cylinder to the
grind position and retracts the piston back to the target load
position in preparation to grind and press the next hamburger
patty, and the controller then actuates the grinder for the grind
duration to fill the cylinder with a quantity of ground meat. For
example, the controller can also initiate a timer for the grind
duration once the grinder is actuated, cease actuation of the timer
once the timer expires, trigger the shear assembly to separate
contents of the cylinder from the output of the grinder (as
described below), actuate the secondary actuator to move the
cylinder out of the grind position and into the weigh position, and
sample the controller 160 to confirm that at least a minimum weight
of ground meat was dispensed into the cylinder.
[0075] In this implementation, if less than the minimum weight of
ground meat is measured in the cylinder, the controller can:
calculate an actual mass flow rate of ground meat during the
preceding grind cycle; calculate a secondary grind duration based
on the actual mass flow rate of ground meat from the grinder and a
difference between the actual and threshold quantity of ground
meat; trigger the secondary actuator to return the cylinder to the
grind position; and actuate the grinder for the secondary grind
duration. The controller can then repeat this process until at
least the threshold quantity of ground meat in the cylinder is
measured.
[0076] In one example of the foregoing implementation, the
controller receives a request for a patty of a mass of at least 100
grams. However, if the actual mass of contents in the cylinder
after an initial grind duration of 50 seconds yields only 95 grams
of meat in the cylinder, the controller can update a grind duration
to grind 100 grams of ground meat from 5.0 seconds to 5.3 seconds,
return the cylinder to the grind position, and actuate the grinder
for a secondary grind duration of 0.3 seconds (i.e., the difference
between the original and the updated grind durations). The
controller can thus predict a new mass of 100.7 grams of ground
meat in the cylinder upon conclusion of the secondary grind
duration and can sample the controller 160 during a succeeding
weigh cycle to confirm this prediction. If greater than 100 grams
of ground meat are thus detected in the cylinder, the controller
can initiate a dispense cycle to release the quantity of ground
meat for cooking. Otherwise, the controller can repeat the forgoing
process until the minimum mass (or weight) of ground meat is loaded
into the cylinder, as shown in FIG. 11.
[0077] As described above, the controller can feed mass flow rate
data collected over the course of one or more grind cycles forward
to calculate a grind duration for a next hamburger patty in order
to maintain a relatively high degree of accuracy in the initial
mass (or weight) of ground meat dispensed into the cylinder, such
as to compensate for different densities and compositions of whole
portions of meat loaded into the hopper over time.
[0078] Furthermore, in this and the preceding implementations, if
an output of the controller 160 indicates that significantly
greater than the target mass of ground meat has been dispensed into
the cylinder, the arm can return the cylinder to the grind
position, and the controller can trigger the actuator system to
drive the piston back toward the unload position (with the shear
plate in the retracted position), thereby returning a portion of
the contents of the cylinder back into the grinder. The controller
can then trigger the shear assembly to move into the advanced
position, thereby severing the contents of the cylinder from the
grinder, and the controller can implement methods described above
to again test the mass (or weight) of ground meat in the cylinder.
For example, the controller can: determine a weight of a first
quantity of ground meat based on an output of the controller 160
upon conclusion of a first grind cycle; trigger the actuation
system to execute a first dispense cycle in response to the weight
of the first quantity of ground meat exceeding a minimum weight
threshold; calculate a second grind duration based on a difference
between the target weight of the hamburger patty and the weight of
the first quantity of ground meat and trigger the grinder to
dispense additional ground meat into the cylinder for the second
grind duration if actual weight of the first quantity of ground
meat is less than the minimum weight threshold for the hamburger
patty, as shown in FIG. 11; and estimate a third grind duration to
form a second hamburger patty in a subsequent grind cycle based on
a sum of the first grind duration and the second grind
duration.
13.4 Grind Cycle: Cylinder Load as Control
[0079] In another implementation, the system 100 determines an
amount and density of ground meat dispensed into the cylinder
during a grind cycle based on deflection of the cylinder away from
the grinder, as shown in FIG. 10. Generally, in this
implementation: the controller can calculate a load position for
the piston based on a target size and/or density of a hamburger
patty; the arm includes a beam supporting the cylinder on a
cantilevered end of the beam just below the outlet of the grinder
in the grind position; the controller 160 can output a signal
corresponding to deflection of the beam from an unloaded position;
the primary actuator constrains the piston in load position during
a corresponding grind cycle; the grinder grinds meat into the
cylinder, wherein proximity of the top of cylinder to the outlet of
the grinder limits discharge of ground meat over the rim of the
cylinder and enables pressure within the cylinder to rise during
the grind cycle; and the grinder can cease dispensation of ground
meat into the cylinder in response to an output of the controller
160 exceeding a threshold value correlated with predicted
deflection of the beam at complete loading of the cylinder for a
given quantity and/or density of ground meat in the cylinder.
[0080] The controller can thus calculate a target load on the arm
(or deflection distance of the arm) for the cylinder to achieve the
preset or target density for the hamburger patty. In particular, as
the grinder fills the cylinder with ground meat during a grind
cycle, ground meat accumulating in the cylinder forces the cylinder
away from the outlet of the grinder, and the controller 160 outputs
a signal corresponding to such load on (or deflection of) the
cylinder relative to the outlet of the grinder. For example, the
controller can pass a target density for the hamburger patty and
the offset distance of the piston below the rim of the cylinder
(i.e., the "load position") into a parametric model specific to a
type of meat loaded into the hopper in order to calculate a target
load on (or target deflection distance for) the cylinder to trigger
conclusion of a grind cycle.
[0081] During the grind cycle, the controller can thus sample the
controller 160 to track such load on (or deflection of) the
cylinder (or load, etc. on the cylinder) and can conclude the grind
cycle once the measured deflection of the cylinder (or load on the
cylinder) exceeds the target deflection distance. Upon conclusion
of the grind cycle, the controller can execute a weigh cycle, as
described above. In particular, if the weight of ground meat in the
cylinder is less than the target weight of ground meat specified in
a corresponding food order, the controller can calculate an
adjusted (i.e., greater) offset distance between the piston and the
rim of the cylinder, shift the piston to this adjusted offset
distance, return the cylinder to the grind position, and actuate
the grinder until the output of the controller 160 indicates that
the target load on (or deflection of) the cylinder has been
achieved before repeating the weigh cycle. During a weigh cycle,
the controller can also calculate an actual density of the quantity
of ground meat in the cylinder, as described above, and update a
target load on (or target deflection of) the cylinder to achieve
the target density--such as in a lookup table or in a parametric
model--commensurate with a difference between the predicted density
and the actual density of the quantity of ground meat dispensed
into the cylinder, and the system 100 can implement this adjusted
target load (or target deflection distance) when adding additional
ground meat to the cylinder in a second grind cycle.
[0082] However, if the measured quantity of ground meat in the
cylinder meets or exceeds the target quantity, the system 100 can
follow the weigh cycle with a dispense cycle. The system 100 can
also implement methods and techniques described above to revise the
offset distance between the piston and the rim of the cylinder
and/or to revise the target load on (or deflection of) the
cylinder--such as in a lookup table or in a parametric model--in
order to achieve greater precision in the quantity and density of
ground meat dispensed into the cylinder during a next grind cycle
for a next hamburger patty, as shown in FIG. 10.
[0083] As described above, the controller can sample the controller
160 while the cylinder is in the grind position to determine a load
on (or deflection of) the cylinder during a grind cycle, and the
controller can sample the same controller 160 (or a second
controller 160) while the cylinder is in the weigh position to
determine a weight or mass of ground meat in the cylinder during a
weigh cycle. For example, in this implementation, the method S100
can further include Block S160, which recites, in response to the
second threshold load corresponding to the target size of the meat
patty exceeding the second load on the cylinder in the weigh
position: calculating an adjusted first threshold load on the
cylinder in the grind position based on a difference between the
second load and the second threshold; returning the cylinder to the
grind position; dispensing additional ground meat from the grinder
into the cylinder; and storing the adjusted first threshold load
for implementation in a subsequent grind cycle for a subsequent
meat patty. In this example, in response to a third load on the
cylinder in the grind position exceeding the adjusted first
threshold load, the system 100 can shift the cylinder to the weigh
position in Block S130 and then execute the dispense cycle in
Blocks S140, S142, and S144 in response to a fourth load on the
cylinder in the weigh position exceeding the second threshold
load.
14. Patty Compression
[0084] In one variation, upon conclusion of a grind cycle and
before initiation of a weight cycle or a dispense cycle, the
primary actuator can drive the piston toward the shear plate to
compress the quantity of ground meat currently in the cylinder
between the piston and the shear plate in order to form a hamburger
patty. For example, upon conclusion of a grind cycle, the
controller can trigger the shear assembly to advance the shear
plate and then trigger the primary actuator to drive the piston
upward by a target distance in order to achieve a patty compaction
level corresponding to a doneness level specified for the hamburger
patty in a food order.
[0085] The system 100 can implement similar methods and techniques
to compact a quantity of ground meat following confirmation that at
least the target amount of ground meat has been loaded into the
cylinder in Block S130. In particular, in the foregoing
implementations, once the target mass (or weight) of ground meat is
confirmed in the cylinder, the controller can trigger the actuator
system to compress the ground meat into a tighter-packed patty by
closing the open end of the cylinder with the shear plate (or other
feature or element within the system 100) and then driving the
piston back toward the top of the cylinder. In one example, once
the minimum amount of ground meat is dispensed into the cylinder:
the secondary actuator can return the cylinder to the grind
position; the controller can set the shear plate in the advanced
position between the output of the grinder and the open end of the
cylinder; and the primary actuator can apply a torque to the second
shaft to drive the piston upward, thereby compressing the ground
meat between the piston and the shear plate. In this example, the
controller can monitor power draw of the primary actuator and/or
the torque output of the primary actuator and can trigger the
primary actuator to drive the piston upward until a target torque
output of the primary actuator--corresponding to a target patty
compression--is detected. Similarly, the controller can sample a
position sensor 164 within the actuator system and can actuate the
primary actuator to drive the piston upward by a target distance
(e.g., 2.0 millimeters) or by a target percentage of the distance
between the top of the cylinder and the face of the piston in the
final load position (e.g., 15%) to achieve a target compression of
the ground meat into a hamburger patty. The system 100 can thus
control the density and/or compaction of a quantity of ground meat
in the cylinder during a grind cycle or upon conclusion of a grind
cycle.
15. Dispense Cycle
[0086] Upon confirmation that a sufficient amount of ground meat
has been loaded into the cylinder, the system 100 can execute a
dispense cycle. Generally, during a dispense cycle, the system 100
can: invert the cylinder in Block S140; and drive the piston toward
the top of the cylinder in Block 142.
[0087] In one implementation, the housing 190 includes: an opening
between the grind position adjacent the grinder and a dispense
position over a cooking surface (or other surface configured to
receive a raw hamburger patty from the cylinder); a door 192
configured to close the opening; and a door actuator configured to
selectively open and close the doors. In this implementation, the
controller can: trigger the door actuator to open the door; then
trigger the secondary actuator to rotate the arm, thereby
positioning the cylinder outside of the housing and into the
dispense position; and finally trigger the primary actuator to
invert the cylinder in Block S140 and to drive the piston into the
unload position in Block S142, thereby discharging the quantity of
ground meat from the cylinder. In this implementation, the door can
be split, as shown in FIG. 10; after opening both sides of the door
and advancing the cylinder out of the housing, the door actuator
can return a first side of the door to a closed position during the
dispense cycle in order to preserve a cool environment within the
housing. To return the cylinder to the grind position in
preparation to form a next hamburger patty, the system 100 can open
the first side of the door, retract the cylinder back into the
housing, and then return both sides of the door to their closed
positions. Furthermore, in this implementation, the sides of the
doors can mate along adjacent inclined surfaces, and the door
actuator can drive an upper side of the door downward onto the
lower side of the door to seal the mating surfaces of the sides of
the door and to seat the perimeter of the door in a receiver around
the opening in the housing in order to limit air exchange between
the interior of the housing and an external environment throughout
operation of the system 100.
[0088] However, the housing can include doors that are hinged and
sprung closed or actively or passively opened and closed in any
other suitable way, and the system 100 can open and close the
door(s) in any other sequence during a dispense cycle to limit air
exchange between the interior of the housing and an external
environment.
[0089] In one variation, the method S100 further includes Block
S150, which recites, following the dispense cycle, recording a
third load on the cylinder in the weigh position and confirming
dispensation of the quantity of ground meat from the cylinder based
on the second load exceeding the third load. Generally, in this
variation, the system 100 can execute a post-dispense weigh cycle
like a weigh cycle described above to confirm that all (or at least
most) of the quantity of ground meat previously loaded in the
cylinder was dispensed during the preceding dispense cycle. For
example, the controller can store a baseline load on the cylinder
or on the arm (e.g., in the form of a baseline output value of the
controller 160) corresponding to an empty cylinder, and the
controller can check that the load on the cylinder or on the arm
has returned to this baseline load (or to within a threshold range
of this baseline) following a dispense cycle. In this example, if a
result of the post-dispense weigh cycle indicates that none (or
less than 10%) of the quantity of ground meat was released from the
cylinder during the dispense cycle, the system 100 can repeat the
dispense cycle to attempt another release. However, if the result
of the post-dispense weigh cycle indicates that between 10% and 90%
of the quantity of ground meat remains in the cycle, the system 100
can discard the remainder of the ground meat in the cylinder, such
as by repeating the dispense cycle, and then issuing an alarm to
the automated foodstuff assembly apparatus to discard the hamburger
patty due to possible fragmentation during the initial dispense
cycle.
[0090] However, the system 100 can handle dispensation of a
quantity of ground meat from the cylinder in any other suitable way
in Blocks S140, S140, and S150.
16. Gas Supply
[0091] One variation of the system 100 further includes a gas
supply 150: configured to supply gas to the cylinder behind the
piston at a first pressure during the grind cycle to limit ingress
of ground meat into the gas ports 122, as shown in FIG. 8; and
configured to supply gas to the cylinder behind the piston at a
second pressure greater than the first pressure during the dispense
cycle to dislodge the quantity of ground meat from the piston, as
shown in FIGS. 10 and 11. Generally, the gas supply 150 functions
to supply gas (e.g., air, humidified air, nitrogen, or another
inert gas, etc.) to a chamber in the cylinder behind the piston and
through ports in the face of the piston at a relatively high flow
rate (or at a relatively high pressure) during a dispense cycle in
order to separate the quantity of ground meat from the face of the
piston, thereby aiding release of the quantity of ground meat from
the cylinder during the dispense cycle. Furthermore, to prevent
meat or related moisture from entering the ports and soiling the
chamber behind the piston, the gas supply 150 can also displace gas
into the chamber behind the piston at a relatively low flow rate
(or at a relatively low pressure) throughout other periods of
operation (e.g., grind cycles, weigh cycles).
[0092] The gas supply 150 can thus execute Block S122 of the method
S100, which recites displacing gas into a chamber in the cylinder
behind the piston at a first pressure during a grind cycle, and
Block S124, which recites displacing gas into the chamber at a
second pressure greater than the first pressure to dispense the
quantity of ground meat, in the form of a patty, from the cylinder
during a dispense cycle.
[0093] In one implementation, the gas supply 150 includes a
reservoir containing pressurized gas, a first valve 151 fluidly
coupled to the reservoir and to the cylinder, a first pressure
regulator set to a first pressure and interposed between the
reservoir and the first valve 151, a second valve 152 fluidly
coupled to the reservoir and to the cylinder, and a second pressure
regulator set to a second pressure greater than the first pressure
and interposed between the reservoir and the second valve 152, as
shown in FIGS. 8 and 10. The gas supply 150 can also include a
conduit extending from the valve(s) to a flexible line tapped into
the cylinder behind the piston; the flexible line can deform as the
cylinder is inverted and righted throughout operation, and the
conduit and flexible line can cooperate to communicate pressurized
gas from the valve(s) to the cylinder. Alternatively, the second
shaft--passing into the cylinder and coupled to the piston via a
crank and connecting rod--can be hollow and can include a port that
communicates gas from the hollow center of the second shaft to the
chamber behind the piston; the conduit can thus be substantially
rigid and can be coupled to the second shaft via a rotatable seal
to communicate pressurized gas from the valve(s) into the cylinder.
However, the gas supply 150 can be fluidly coupled to the cylinder
in any other way.
[0094] In the foregoing implementation, the controller can
selectively open the first valve 151 for a first duration of time
during the grind cycle (e.g., for the entirety of the grind cycle
and subsequent weigh cycle) in order to limit ingress of meat and
fluids past the piston; and the controller can selectively open the
second valve 152 for a second duration of time less than the first
duration of time during the dispense cycle (e.g., for a burst of
one second) in order to dislodge the quantity of meat from the
cylinder.
[0095] Alternatively, the gas supply 150 can include a pump, and
the controller can selectively activate the pump to pump gas (e.g.,
air) into the cylinder at different pressures or at different flow
rates based on the current state of the system 100, such as whether
the system 100 is currently in a grind cycle or in a dispense
cycle. However, the gas supply 150 can include any other one or
more reservoirs, valves, and/or pumps configured to supply gas to
the cylinder at two or more flow rates or pressures throughout
operation of the system 100.
17. Mixed-Meat Patty
[0096] In one variation, the system 100 is configured to form a
hamburger patty from multiple types of meat. In this variation, the
system 100 includes a set of grinder modules arranged within the
housing, wherein each grinder module includes a hopper and a
grinder and is configured to grind and dispense a unique type of
meat (e.g., beef, lamb, chicken, or turkey, etc.) or a unique meat
blend (e.g., 80% beef and 20% turkey, 50% lamb and 50% bison).
[0097] In one implementation, the system 100 includes a magazine
186 supporting each of the grinder modules and configured to
selectively position each grinder module in the grind position over
the cylinder based on a callout for a particular meat type or
combination of meat types in a food order received in Block S110.
Generally, in this implementation, the controller can trigger the
magazine 186 to selectively reposition a particular grinder module
into the grind position and can selectively actuate its grinder to
dispense a volume of ground meat of the corresponding meat type
from the particular grinder module into the cylinder. For example,
the housing can include a first grinder module loaded with whole
portions of beef, a second grinder module loaded with whole
portions of lamb, and a third grinder module loaded with whole
portions of turkey. In this example, upon receipt of an order for a
hamburger with a 30%-beef and 70%-turkey hamburger patty, the
controller can: index the first grinder module into the grind
position; actuate the first grinder actuator for a first calculated
grind duration (described above) sufficient to achieve 30% of the
target weight of the hamburger patty in beef or until the piston is
displaced--by ground beef--by 30% of the distance toward the final
calculated load position for the target size of the hamburger patty
during a first grind cycle; execute a first weigh cycle to confirm
the amount of beef loaded into the cylinder, as described above;
and trigger the magazine 186 to index the third grinder module into
the grind position. The system 100 can then actuate the third
grinder for a second calculated grind duration sufficient to
achieve 70% of the target weight of the hamburger patty in turkey
or until the piston is displaced--by ground turkey--to the final
calculated load position for the target size of the hamburger patty
during a second grind cycle; execute a second weigh cycle to
confirm the amount of turkey loaded into the cylinder; and then
execute a dispense cycle to release the mixed-meat hamburger patty
onto an adjacent cooking surface. Thus, in this implementation, the
system 100 can create a single hamburger patty with multiple layers
of distinct types of meat.
[0098] In the foregoing implementation, the system 100 can layer
distinct types of meat in the patty based on preferred cooking
temperatures for the distinct types of meats supported in the
housing and can interface with an external cooking surface to cook
distinct meat types in one patty at corresponding preferred
temperatures. For the example above in which the system 100 forms a
hamburger patty with a 30%-beef lower layer and a 70%-turkey upper
layer, the system 100 can invert and dispense the hamburger patty
beef-side up into a double-sided griddle; the automated foodstuff
assembly apparatus can then bring an upper cooking surface of the
double-sided griddle into contact with the beef-side of the patty
and heat the upper cooking surface to a preferred temperature for
cooking beef (e.g., 450.degree. F.). The automated foodstuff
assembly apparatus can also bring a lower cooking surface of the
double-sided griddle--in contact with the turkey-side of the
patty--to a preferred temperature for cooking turkey (e.g.,
410.degree. F.).
[0099] Alternatively, in this variation, the system 100 can include
a mixer configured to mix contents of the cylinder once a
particular ratio of various meat types is dispensed into the
cylinder. For example, once a specified amount of two or more
distinct meat types is dispensed from two or more grinder modules
into the cylinder, the arm can advance the cylinder to a mix
position adjacent the mixer (e.g., between the grind position and
the dispense position), and the mixer can mix the contents of the
cylinder, such as for a preset period of time or until a threshold
uniformity is reached. The actuation system can then return the
cylinder to the grind position, the shear assembly can advance the
shear plate over the cylinder, and the actuator system can rack the
piston (i.e., drive the piston upward) to compress the patty, as
described above, prior to dispensing the mixed-meat patty onto a
cooking surface.
[0100] In this variation each grinder module can include discrete
actuators configured to drive its upper and lower augers and to
actuate its grinder. Alternatively, the system 100 can include a
single set of auger and grinder actuators configured to engage
corresponding input shafts of a hopper and a grinder of a
particular grinder module when the magazine 186 positions the
particular grinder module in the grind position.
[0101] In a similar implementation, the system 100 can include a
set of static grinder modules, and the arm can selectively
transition the cylinder to dispense positions at each grinder
module to collect a target amount of ground meat from each grinder
module, such as based on a specification for hamburger patty
composition included in a custom food order received from a patron
in Block S110. The controller can thus trigger the secondary
actuator to sequentially position the cylinder into select dispense
positions adjacent each grinder module based on meat types loaded
into each grinder module and based on an order for a hamburger
patty specifying particular amounts (e.g., percentages, masses,
volumes) of such meat types.
18. Multiple Hoppers
[0102] In one variation shown in FIG. 8, the system 100 includes: a
set of hoppers 180, wherein each hopper in the set of hoppers 180
is configured to store whole portions of meat, defines an outlet
configured to couple to an inlet of the grinder, and includes a
hopper piston opposite the outlet; a magazine 186 configured to
support each hopper in the set of hoppers 180 and to selectively
position each hopper, in the set of hoppers 180, in a discharge
position to supply whole portions of meat to the grinder; and a
hopper actuator configured to drive a hopper piston of a hopper in
the discharge position toward the grinder to feed whole portions of
meat into the grinder.
[0103] Generally, in this variation, the system 100 includes
multiple hoppers configured to individually feed whole portions of
meat into a single grinder. In particular, each hopper can be
loaded with a quantity of unground meat and then loaded into the
magazine 186; when a first hopper in the set is fully emptied of
meat, the magazine 186 can index the magazine 186 forward to
replace the now-empty first hopper with a full second hopper in
order, as shown in FIG. 8, to enable the system 100 to continue to
form hamburger patties (e.g., according to the method S100) without
pause.
[0104] In one implementation, each hopper includes: a tube, such as
a tube or cylinder cross-section defining an outlet; and a piston
arranged within the tube opposite the outlet. In this
implementation, the hopper can be loaded with whole portions of raw
meat between the piston and the outlet and then installed in the
magazine 186 inside the housing along with other like hoppers. In
this implementation, the hopper actuator can include a linear
actuator; thus, when the magazine 186 positions a particular hopper
in the set in a discharge position, the outlet of the particular
hopper can be aligned with and sealed over an inlet of the grinder,
and the linear actuator can engage the piston opposite the whole
portions of raw meat and can drive the piston toward the outlet of
the particular hopper in order to drive whole portions of raw meat
into the grinder, as shown in FIG. 9. Alternatively, the hopper
actuator can include a pressure chamber configured to seal over the
rear of the particular hopper in the discharge position and that is
configured to pressurize a volume behind the piston in order to
drive the piston toward the inlet of the grinder, as shown in FIG.
8. In this implementation, once the piston in the particular hopper
in the discharge position is fully advanced to the outlet of the
particular hopper such that few or no whole portions of raw meat
remain in the hopper, the controller can trigger the magazine 186
to index the particular hopper to a discard position and to
(simultaneously) advance a second hopper--currently filled with
whole portions of raw meat--into the discrete position. The hopper
actuator can then similarly advance the piston of the second hopper
forward, as described above. The system 100 can repeat this process
over time as the hoppers in the magazine 186 are emptied.
[0105] Alternatively, in this variation, hoppers installed in the
magazine 186 can be loaded with different types of meat, and the
magazine 186 can selectively position a hopper in the discharge
position based on a type of meat loaded into the hopper and a type
of meat specified for a hamburger patty currently in process, as
shown in FIG. 9. In this variation, because remnants of a first
type of meat may remain in the grinder after a first hopper in the
discharge position is replaced with a second hopper containing a
second type of meat, the system 100 can further include an
intermediate container 112 configured to collect ground meat
remnants from the grinder between a hopper exchange cycle in which
the magazine 186 exchanges one hopper containing one type of meat
for another hopper containing another type of meat during an
exchange cycle. For example, the intermediate container 112 can
define a cup of sufficient internal volume substantially equivalent
to an internal open volume of the grinder such that the
intermediate container 112 can hold substantially all ground meat
discharged from the grinder during an exchange cycle. The
intermediate container 112 can be supported on a second arm
configured to selectively position the intermediate container 112
under the outlet of the grinder to receive ground meat from the
grinder during an exchange cycle and configured to retract the
intermediate container 112 from the grinder to permit the actuation
system to move the cylinder into the grind position. The second arm
can be actuated by a second actuation system, and the second
actuation system can also be configured to elevate the intermediate
container 112 over the cylinder and to invert the intermediate
container 112 to dispense contents of the intermediate container
112 into the cylinder, such as in response to receipt of a request
for a hamburger patty containing a meat type previously dispensed
into the intermediate container 112 during a former exchange cycle.
The intermediate container 112 and the second actuator system can
thus define a structure substantially similar to the cylinder and
the actuation system and can cooperate with the cylinder and the
actuation system to recycle ground meat of a first type--previously
discharged from the grinder during a discharge cycle in preparation
to grind another meat type dispensed from another hopper--by
returning this ground meat to the cylinder to form a hamburger
patty of the first meat type. Alternatively, as shown in FIG. 9,
the system 100 can include an intermediate container 112 defining a
second cylinder and a second piston and including a second actuator
system like the cylinder, the piston, and the actuator system
described above, and the system 100 can selectively position the
cylinder and the second cylinder in the grind position to form
hamburger patties and to store ground meat discharged from the
grinder during an exchange cycle based on meat types specified in a
food order received in Block S110.
[0106] In one example: the set of hoppers 180 includes a first
hopper containing whole portions of meat of a first type and a
second hopper containing whole portions of meat of a second type
distinct from the first type; and, in response to receipt of a food
order specifying meat of the second type when the first hopper is
in the discharge position, the grinder grinds remnants of meat of
the first type contained in the grinder into the intermediate
canister, the magazine 186 exchanges the first hopper for the
second hopper, the hopper actuator drives the hopper piston of the
second hopper toward the outlet of the second hopper, the grinder
grinds whole portions of meat of the second type into the cylinder,
and the system 100 implements methods and techniques described
above to form, weigh, and dispense the quantity of meat of the
second type.
[0107] The system 100 can therefore include multiple hoppers
containing various types of meat, and the system 100 can trigger
the magazine 186 to selectively position these hoppers in the
discharge position to serve whole portions of ground meat to the
grinder based on a food order specifying a hamburger patty of one
or more meat types. However, the system 100 can include any other
number and/or form of hoppers, grinders, cylinders, intermediate
canisters, and/or actuator systems to enable the system 100 to form
hamburger patties containing various types of meat.
19. Cylinder Variations
[0108] In one variation, the system 100 excludes the piston, and
the cylinder defines a frustoconical internal volume that is
tapered vertically downward in the upright position. In this
variation, the actuator system can further include a vibrator
assembly (e.g., a rotary motor and a rotating eccentric mass) that
is actuated as the actuator system inverts the cylinder to dispense
a patty contained therein onto an adjacent cooking surface, thereby
oscillating the patty at a relatively high frequency and low
amplitude to release the patty from the cylinder. In this
variation, the actuator system can also jostle the cylinder at a
relatively low frequency and at a relatively high amplitude once
the cylinder is inverted to further coax the patty out of the
cylinder during a dispense cycle.
[0109] In a similar variation, the system 100 excludes the piston
and the actuator system, and the cylinder defines a frustoconical
internal volume that is tapered vertically upward. In this
variation, the system 100 includes a vibrator assembly coupled to
the arm, and the controller activates the vibrator assembly when
the cylinder is in the dispense position to coax a patty contained
therein out of the cylinder and onto an adjacent cooking surface
during a dispense cycle.
[0110] In another variation, the cylinder includes split halves,
and the cylinder actuator system selectively opens the halves of
the cylinder to release a patty contained therein onto an adjacent
cooking surface.
[0111] However, the cylinder can define any other suitable
geometry, and the patty grinding system can include any other
actuator or subsystem to dislodge a patty from the cylinder and to
release the patty onto an adjacent cooking surface.
[0112] As a person skilled in the art will recognize from the
previous detailed description and from the figures and claims,
modifications and changes can be made to the embodiments of the
invention without departing from the scope of this invention as
defined in the following claims.
* * * * *